Negative mold comprising predefined foam blocks for casting a component and method for producing the negative mold

ABSTRACT

A negative mold for casting a component such as a blade of a wind turbine is described. The negative mold includes a support structure and a plurality of foam blocks, which are mounted to the support structure in such a manner, that a common surface contour of the plurality of foam blocks defines an outer surface of the component, which is to be casted. Each foam block of the plurality of foam blocks is taken from a predetermined number of different types of foam blocks, each type of foam block is defined by a predetermined foam block size and foam block shape. A method for producing such a negative mold is also described.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. patent application Ser. No.13/171,785 filed Jun. 29, 2011, which claims the priority of EuropeanPatent Office application No. 10007254.5 EP filed Jul. 14, 2010. All ofthe applications are incorporated by reference herein in their entirety.

TECHNICAL FIELD

The present invention relates to the technical field of producingcomponents by means of a casting procedure. The component may be astructural component of a wind turbine such as a blade of a windturbine. In particular, the present invention relates to a negative moldfor casting a component and to a method for producing a negative moldfor casting a component.

BACKGROUND

A blade for a rotor of a wind turbine is typically produced by means ofa casting procedure. The casting procedure for a new type of windturbine blade comprises (a) producing a positive mold representing adesign model of the blade which is supposed to be produced, (b)producing a negative mold representing negative copy of the positivemold and (c) producing the blade by casting an appropriate bladematerial into the negative mold. Thereby, each step has to be finishedbefore starting the next step.

In this document a positive mold is also denominated as a male mold, apositive form and/or a plug. A negative mold is also denominated as afemale mold, a negative form and/or a casting mold.

The positive mold respectively the plug is typically produced by meansof a milling process, which is accomplished by means of a large ComputerNumerical Controlled (CNC) milling machine. Thereby, due to materialproperties a sub-frame for the positive mold is required having thegeneral geometrical shape of the positive mold. On the sub-frame softercomposite material layers are laid down between harder curable materialslike fiberglass. The softer composite material layers can be processedby a milling procedure. Because of the large dimension of the positivemold such a milling process lasts typically 8 to 10 weeks.

US 2009/0084932 A1 discloses a negative mold for casting a wind turbineblade. The negative mold comprises a plurality of spaced-apart joists,wherein each joist has an edge configuration generally corresponding toa form of the blade. The negative mold further comprises a flexibleframe, supported by the edges of the joists, for shaping an exteriorsurface of the blade. On the flexible frame there are formed differentcoatings layers. (A) A first coating layer includes a rigid, semi-rigid,and/or flexible spray foam, such as a polyurethane foam. Such lowdensity, expanding materials for the first coating (a) will fill anyopenings in the flexible frame, (b) provide improved structural rigiditywith little increase in weight and (c) are relatively easy to machine.Once the first coating layer is applied and cured, the surface of thefirst layer may be cut, ground, sanded and/or otherwise formed to ashape that more-closely corresponds to the intended external shape ofthe blade. In particular, the first layer may be machined withcomputer-controlled equipment so as to provide exactly the desiredshape. (B) A second coating layer may be applied as a protective layerof higher density material, such as filled or unfilled plastic resins.In addition to enhancing durability of the negative mold, the secondcoating layer also provides a smooth surface against which to form theblade.

When using the negative mold disclosed in US 2009/0084932 A1 forproducing a wind turbine blade it is not necessary to produce a positivemold first. The disclosed negative mold can be produced directly basedon three dimensional data representing the geometry of the wind turbineblade which is supposed to be casted. However, the disclosed negativemold has the disadvantage that building up the negative mold is a ratherelaborate procedure.

There may be a need for a negative mold for casting a component such asa wind turbine blade, wherein the negative mold can be build up in aneasy and effective manner.

SUMMARY

This need may be met by the subject matter according to the independentclaims. Advantageous embodiments of the present invention are describedby the dependent claims. According to a first aspect of the inventionthere is provided a negative mold for casting a component, in particularfor casting a blade of a wind turbine. The provided negative moldcomprises (a) a support structure and (b) a plurality of foam blocks,which are mounted to the support structure in such a manner, that acommon surface contour of the plurality of foam blocks defines an outersurface of the component, which is supposed to be casted. Each foamblock of the plurality of foam blocks is taken from a predeterminednumber of different types of foam blocks, whereby each type of foamblock is defined by a predetermined foam block size and foam blockshape.

The described negative mold is based on the idea that for building upthe negative mold it is not necessary to use individually shaped foamblocks, which are adapted to the geometry of the component, which issupposed to be casted. According to the invention the foam blocks arerather selected from a limited number of standardized foam block types,which are defined with respect to their geometry respectively withrespect to their size and shape. This may provide the advantage thatwhen building up the described negative mold one has to store only alimited number of different types of foam blocks which makes the castingof the component very effective.

Generally speaking, the described negative mold is build up in a modularway, wherein each module is taken from the limited number of differenttypes of foam blocks.

The support structure may be a frame and in particular a metal frame.The foam blocks may be mounted or attached to the support structure forinstance by using an appropriate glue.

According to an embodiment of the invention the predetermined number isnot exceeding the number eight, in particular not exceeding the numberfive and preferably not exceeding the number three. This may provide theadvantage that the negative mold can be produced in a very efficientmanner. Generally speaking, the smaller the predetermined number is, thelarger is the efficiency in particular with respect to the effort forstoring or repositing the foam blocks before assembling them together atthe support structure.

For instance if the casted component is a blade of a wind turbine it isconsidered that the number of different shaped foam blocks can belimited to 3, 4 or 5.

According to a further embodiment of the invention each foam blockcomprises at least one lateral side surface having a three dimensionalcontour, whereby adjoining lateral side surfaces of different foamblocks have complementary contours. This may provide the advantage thatthe foam blocks can be arranged next to each other with a closeconnection and a minimum gap in between two neighboring foam blocks.

The contour may have any arbitrary three dimensional shape. A firstcontour may be for instance a protrusion and a second complementarycontour may be for instance a recess. According to a further embodimentof the invention a first three dimensional contour comprise a convexgeometry and a second three dimensional contour comprises acomplementary concave contour.

The convex and/or the concave geometry may be for instance a section ofa cylinder. This means that in a cross sectional view of the respectivefoam block the convex respectively the concave geometry appears as asection of a circle. Preferably, the convex respectively the concavegeometry appears as a half circle. This may provide the advantage thatthe three dimensional contours can be easily formed. Further, a veryclose connection or a minimal gap between neighboring foam blocks can berealized.

According to a further embodiment of the invention at least one foamblock of the plurality of foam blocks is a cut foam block, which hasbeen produced by cutting a foam block, which is of a type of one of thepredetermined number of different types of foam blocks. This may providethe advantage that the geometry of the negative mold can be easilyadapted to the geometry of the component to be casted. Thereby, it isnot necessary to increase the predetermined number of different types offoam blocks in order to realize a precise adaptation of the geometry ofthe negative mold to the component to be casted. According to a furtherembodiment of the invention the negative mold further comprises aplurality of foam pieces, wherein in a cross sectional view of thenegative mold a first foam piece is located at one end of the negativemold and a second foam piece is located at an opposing other end of thenegative mold. Thereby, the foam pieces are made from a foam materialhaving a density, which is larger than the density of the foam materialbeing used for the foam blocks. This may provide the advantage that theend foam pieces of the negative mold are mechanically more stable thanthe middle foam blocks. As a result, the end foam pieces may serve as amounting structure, which are used for mounting the negative mold to thesupport structure.

The foam pieces may have the shape of a flange, which has the advantagethat a mounting of the foam pieces to the support structure isfacilitated.

The foam material being used for the foam blocks may have a densitywithin the range between 250 kg/m3 and 400 kg/m3. By contrast thereto,the foam material being used for the foam pieces may have a densitywithin the range between 500 kg/m3 and 700 kg/m3. In particular, thefoam material being used for the foam pieces may have a density ofapproximately 600 kg/m3.

Apart from having a smaller weight a reduced density of the foam blocksmay further have the advantage that a surface finishing of the foamblocks and in particular a milling of the foam blocks will befacilitated.

According to a further embodiment of the invention the common surfacecontour has been generated by a finishing procedure, which comprises amilling of at least some of the foam blocks. This may provide theadvantage that excess foam material is removed easily leaving aprecisely shaped common surface contour.

The milling may have been carried out with a milling machine, inparticular a Computer Numerical Controlled (CNC) milling machine.Thereby, the milling procedure may be based on three dimensional data ofthe negative mold. The negative mold or at least portion(s) of thenegative mold can be milled directly with a CNC milling machine having alarge gantry, a large track and/or a large robotic arm. This may be inparticular advantageous if the component to be casted is a very largecomponent such as a blade of a wind turbine.

By directly milling the negative mold a time consuming, elaborate andcostly process of producing a positive mold of the component beingsupposed to be casted can be completely omitted.

According to a further embodiment of the invention the finishingprocedure comprises a forming a surface layer on the milled commonsurface contour. This may provide the advantage that even small cracksand/or pores, which may be still present within the milled commonsurface contour, can be filled. The surface layer can be applied orformed for instance by spraying a surface layer onto the common surfacecontour.

The surface layer may comprise at least one of the group of (a) asemi-permanent release agent, (b) Teflon and (c) a plastic bag materialsuch as polypropylene or any other thermoplastic material. This mayprovide the advantage that in the casting process the negative mold andthe casted component are separated from each other. Hence, there is nodirect contact between the negative mold and the casting such that thereis no requirement to prepare a special inner surface of the negativemold. The described surface layer may further provide the advantage thatafter a casting has been finished the casted wind turbine blade can beeasily removed from the negative mold.

Compared to a known release agent the semi-permanent release agent hasthe advantage that it will stay within the negative mold or on the innersurface of the negative mold at least for some castings. Therefore, aplurality of castings can be made before new semi-permanent releaseagent has to be added in order to replace the in the meantime consumedsemi-permanent release agent.

In this respect it is mentioned that on top of the surface layer it isof course possible to apply a usual release agent. Such a release agentmay further contribute that after a finished casting process the castedwind turbine blade can be easily removed from the negative mold.

The surface layer may be applied on the synthetic material representingthe mold surface for instance by means of a coating spray and/or apowder coating of e.g. Teflon. A spray material being used for coatingthe mold may fuse to the casting at the correct temperature. It ismentioned that also other appropriate materials for coating the mold maybe used. According to a further embodiment of the invention the foamblocks are made out of a material, which is dimensionally stable up to atemperature of at least 100° C., preferably up to a temperature of atleast 120° C. and in particular up to a temperature of at least 140° C.This may provide the advantage that a variety of new processes andprocedures become available for producing a negative mold for casting awind turbine blade.

According to a further embodiment of the invention the materialcomprises at least one of (a) a pourable epoxy foam, (b) a polyurethanefoam, (c) a glass foam, (d) a high temperature resin, and/or (e) athermoplastic material.

The material, in particular the pourable epoxy foam can be directlycasted into a block shape. Thereby, the mold may be build up from aplurality of different blocks, which are spatially arranged to eachother in a manner, which is defined by the shape of the wind turbineblade. The blocks may be made in particular by cutting larger forms ofextruded material into an appropriate block shape. When using thedescribed material having a high dimensional stability up totemperatures greater than 100° C., tensions within the block materialand later within the whole mold can be significantly reduced.

Using appropriate shaped blocks for building up the mold may provide theadvantage that the above mentioned milling can be performed easily.

It is mentioned that when using the described temperature stablematerial a variety of different processes will become available when themold is capable of sustaining temperatures greater than at least 100° C.

According to a further aspect of the invention there is provided amethod for producing a negative mold for casting a component, which isin particular a blade of a wind turbine. The provided the methodcomprises (a) providing a support structure, (b) mounting a plurality offoam blocks to the support structure in such a manner, that a commonsurface contour of the plurality of foam blocks defines an outer surfaceof the component, which is supposed to be casted. Each foam block of theplurality of foam blocks is taken from a predetermined number ofdifferent types of foam blocks, whereby each type of foam block isdefined by a predetermined foam block size and foam block shape.

Also the described method is based on the idea that for building up thenegative mold a modular construction kit can be used, which comprises alimited number of standardized foam block types, which are defined withrespect to their geometry respectively with respect to their size andshape. When building up the described negative mold one has to storeonly a limited number of different types of foam blocks which makes thecasting of the component very effective.

According to an embodiment of the invention the method furthercomprises, before mounting the plurality of foam blocks to the supportstructure, arranging the plurality of foam blocks in a preorderedmanner, wherein foam blocks of one and the same type are stored in oneand the same storing region. This may provide the advantage that aworkman who is mounting the foam blocks to the support structure canwork in a proper, orderly and/or uncluttered environment. In particular,when an external supplier is used for providing the foam blocks therespective foam blocks can be delivered already by the external supplierto the respective storing region.

In other words, the preordered arrangement of the foam blocks makes thework for a workman very easy. In particular an installation ofappropriate foam pieces to the support structure and/or a trimming ofthe edges between different foam blocks can be carried out by usingtraditional handwork techniques.

It has to be noted that embodiments of the invention have been describedwith reference to different subject matters. In particular, someembodiments have been described with reference to apparatus type claimswhereas other embodiments have been described with reference to methodtype claims. However, a person skilled in the art will gather from theabove and the following description that, unless other notified, inaddition to any combination of features belonging to one type of subjectmatter also any combination between features relating to differentsubject matters, in particular between features of the apparatus typeclaims and features of the method type claims is considered as to bedisclosed with this document.

The aspects defined above and further aspects of the present inventionare apparent from the examples of embodiment to be described hereinafterand are explained with reference to the examples of embodiment. Theinvention will be described in more detail hereinafter with reference toexamples of embodiment but to which the invention is not limited.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1a shows in a cross sectional view a negative mold for casting awind turbine blade, wherein the negative mold comprises a plurality offoam blocks, which are taken from a predetermined limited number ofdifferent types of foam blocks.

FIG. 1b shows different types of foam blocks, which are used forbuilding up the negative mold shown in FIG. 1 a.

FIG. 2a shows a sectional view of a portion of a negative mold inaccordance with a first embodiment of the invention.

FIG. 2b shows a sectional view of a portion of a negative mold inaccordance with a second embodiment of the invention.

DETAILED DESCRIPTION

The illustration in the drawing is schematically. It is noted that indifferent figures, similar or identical elements are provided with thesame reference signs or with reference signs, which are different fromthe corresponding reference signs only within the first digit.

FIG. 1a shows in a cross sectional view a negative mold 100 for castinga wind turbine blade. The negative mold 100 has been built on a supportstructure or frame, which for the sake of clarity is not depicted inFIG. 1a . The negative mold 100 comprises a plurality of foam blocks.According to the embodiment described here each foam block is either afoam block 152 of a first type, a foam block 154 of a second type or afoam block of a third type 158 a, 158 b. In addition, the negative moldcomprises a cut foam block 156, which has been produced by cutting off aportion of a foam block of the first type.

Compared to the inner foam blocks 152, 154 b and 156 the outer foamblocks 158 a, 158 b have to sustain a larger mechanical load. Therefore,according to the embodiment described here the outer foam blocks 158 aand 158 b are made from a foam material, which has a larger density thanthe foam material being used for the inner foam blocks 152, 154 and 156.In this document the outer foam blocks 158 a and 158 b, which aredenominated foam pieces or foam end pieces, are made from a foammaterial having a density 600 kg/m3. By contrast thereto, the inner foamblocks 152, 154 and 156 are made from a material having a densitybetween 250 kg/m3 and 400 kg/m3.

When producing the negative mold 100 all the foam blocks and foam endpieces are placed onto the non depicted frame in an appropriate manner.Thereby, the foam blocks and foam end pieces are connected to each otherin such a manner, that complementary three dimensional contours of thelateral side surfaces adjoin each other. Specifically, as can be seenfrom FIG. 1b , a foam block 152 comprises a first lateral side surface152 a having a concave shape and an opposing second lateral side surface152 b having a convex shape. Accordingly, a foam block 154 comprises afirst lateral side surface 154 a having a concave shape and an opposingsecond lateral side surface 154 b having a convex shape.

After having placed all foam blocks and foam end pieces at the frame amilling procure is started for finishing the surface of the negativemold 100. Thereby, all material, which is located above a common surfacecontour 160, is milled away. By employing the described millingprocedure a common surface contour 160 can be obtained, which is veryeven or flat and which precisely matches to the outer surface of thecomponent, which is supposed to be casted within the negative mold 100.

It is mentioned that after the described milling also other finishingprocedures can be applied, which may further improve the surface qualityfor the negative mold 100. More details will be given below withreference to FIGS. 2a and 2 b.

In this respect it is mentioned that FIG. 1a does not show a crosssection of a complete negative mold. FIG. 1a only shows a lower half 100of a negative mold for casting a blade of a wind turbine. Thereby, thelongitudinal extension (from the root to the tip) of the blade isorientated perpendicular to the plane of drawing of FIG. 1 a.

FIG. 2a shows in an enlarged sectional view a portion of the negativemold 100, which is now denominated with reference numeral 200. Thenegative mould 200 comprises a frame structure 205, which is made frommetal and which already has the basic shape of the negative mold 200. Ontop or above the frame structure 205 there is formed a fiberglass layer215.

The fiberglass layer 215 comprises a composite material being able towithstand high temperatures, which might occur during a casting process.On top or above the fiberglass layer 215 there is formed an epoxy foam250, which according to the embodiment described here is a high densityand high temperature epoxy foam having a density between 250 kg/m3 or400 kg/m3. As has already been mentioned above, the precisely shapedupper surface of the epoxy foam 250 has been generated by means of asurface finish 275, which has been accomplished by a precise millingprocedure of the epoxy foam 250.

It is mentioned that optionally one or more epoxy layers may beintroduced below or instead of the surface finish 275. Such epoxy layersmay provide a seal for the negative mold. This may prevent humidity fromentering the negative mold. Therefore, unwanted humidity inducedcontractions or expansions of the negative mold can be effectivelyavoided.

It is further mentioned that on the surface finish 275 or on the epoxyfoam (instead of the surface finish) there may be applied asemi-permanent release agent, which will stay within the negative moldand/or on the inner surface of the negative mold at least for somecastings. The semi-permanent release agent may allow that a plurality ofcastings can be made before a new semi-permanent release agent has to beadded in order to replace in the meantime consumed semi-permanentrelease agent.

The semi-permanent release agent may be for instance a water basedsemi-permanent release agent or a solvent based semi-permanent releaseagent. Preferably, a water based semi-permanent release agent is usedbecause it may be non toxic and/or may allow for an easy handlingwithout the need for specific handling equipment.

Furthermore, it is mentioned that on the surface finish 275 or insteadof the surface finish 275 a Teflon layer or a plastic bag material suchas polypropylene may be formed. According to the embodiment describedhere a temporary mold the epoxy foam blocks 152, 154 and 156 (see FIG.1a ), which have been precast to the correct height and form, are gluedonto the fiberglass layer 215. The epoxy foam is then poured over thesurface and then covered with a stiff yet flexible material such aspolypropylene. The foam then expands to the correct height and theflexible portions of the negative mold can be removed.

In the following there will be mentioned some treatments which are alsopossible in order to realize a smooth inner surface of the commonsurface contour of the negative mold:

(a) One or several sprayed epoxy layer(s) can be sanded in betweendifferent coatings.

(b) A layer of epoxy can be rolled on by hand and can be distributed bya silicon leveling tool.

(c) Coating the inner surface by using a spray gel.

As has already been mentioned above, on top of this smooth inner surfacea semi-permanent release agent may be applied followed optionally by aTeflon layer.

Another method in order to realize a smooth inner surface of thenegative mold is to simply use a “plastic bag” directly on top of theepoxy foam. The “plastic bag method” may be realized by a continuoussheet of polypropylene or some other thermoplastic, which is placed onthe inner surface of the negative mold. In this case there will be nodirect contact between the negative mold and the casting (i.e. thecasted wind turbine blade) such that no special surface treatment isrequired.

In the following a possible process for realizing the negative mold 200will be described (work description):

-   -   In a first step the frame 205 is prepared with a surface having        approximately the same shape as the finished negative mold,        minus the expected thicknesses of the epoxy foam 250 and the        fiberglass layer 215.    -   In a second step the fiberglass layer 215 is added on top of the        frame 205.    -   In a third step the epoxy foam 250 (poured in appropriate        blocks) are glued onto the fiberglass layer 215.    -   In a fourth step the epoxy foam 250 is milled into the correct        and final shape.

FIG. 2b shows in an enlarged sectional view a negative mold 200according to a second embodiment of the invention. In accordance withthe negative mold 200 shown is FIG. 2a , the negative mold 200 alsocomprises a (metal) frame 205, a fiberglass layer 215 formed on theframe 205 and an epoxy foam 250.

However in contrast to the negative mold 200 shown in FIG. 2a thenegative mold 200 respectively the foam blocks of the negative mold 200comprise additionally a further layer of epoxy foam 220 and a furtherfiberglass layer 235 formed on the epoxy foam 220. The additional epoxyfoam layer 220 and the additional fiberglass layer 235 may provide theadvantage that additional stability may be provided to the structure ofthe negative mold 200 shown in FIG. 2b . Because of the provision of thefurther fiberglass layer 235 the final negative mold 200 will be able towithstand an increased number of castings.

In the following there will be described some advantages, which resultfrom using the negative molds 100, 200 described in this document.

(A) By using a directly milled negative mold which makes the traditionalprocedure of forming a positive mold respectively a plug superfluous, anew wind turbine blade can be casted and can be ready for testing inapproximately half the time which is required to traditionally produce(a prototype of) a wind turbine blade.(B) Casting a blade in a directly milled negative mold produces a moldgeometry that closer matches the original. Further, the angles of anegative mold can be milled more precisely than that of a positive mold,because the milling head of a milling machine has more clearance. Thisresults in less hand finishing of the geometry of the negative mold.(C) The negative mold may by a high temperature negative mold which iscapable of withstanding approximately twice the temperature which atraditionally produced negative mold is able to sustain.(D) The production of the directly produced negative mold is preciselyrepeatable by a recreation of a file including 3D data.(E) Compared to the traditional process for producing a negative moldthe described single step production process of the negative mold savestime and money.(F) There is no need for a special storage of a positive mold.(G) All components of the described negative mold are resistant tomoisture.(H) The directly produced negative mold can be realized with asimplified composite layer using only few raw materials.(I) In a curing process only a very small mechanical tension occurswithin the negative mold in particular if the above described materialsare used. Therefore, a simplified frame structure can be used.

Last but not least it is mentioned that negative molds that are worn outcan easily be refurbished to the exact geometry by milling down theupper surface and pour out new layer of epoxy foam. This is a greatimprovement compared to prior art negative molds where one need to startfrom the bottom by building up a new negative mold by casting, whereinin the beginning a positive mold respectively a plug has to be used.

It should be noted that the term “comprising” does not exclude otherelements or steps and the use of articles “a” or “an” does not exclude aplurality. Also elements described in association with differentembodiments may be combined. It should also be noted that referencesigns in the claims should not be construed as limiting the scope of theclaims.

LIST OF REFERENCE SIGNS

-   -   100 negative mold (lower half)    -   152 foam block (first type)    -   152 a lateral side surface/concave shape    -   152 b lateral side surface/convex shape    -   154 foam block (second type)    -   154 a lateral side surface/concave shape    -   154 b lateral side surface/convex shape    -   156 cut foam block    -   158 a foam end piece (third type)    -   158 b foam end piece (third type)    -   160 common surface contour    -   200 negative mold    -   205 frame    -   215 fiberglass layer    -   220 epoxy foam    -   235 fiberglass layer    -   250 epoxy foam    -   275 surface finish

The invention claimed is:
 1. A method for producing a negative mold forcasting a blade of a wind turbine component, comprising: providing asupport structure; and adjacently mounting a plurality of foam blocksonto the support structure such that a common surface contour of theplurality of foam blocks defines an outer surface of the wind turbinecomponent, which is to be casted; and wherein each foam block is takenfrom a predetermined number of different types of foam blocks, each ofthe different types of foam block is defined by a predetermined foamblock size and foam block shape, wherein each of the mounted foam blockscomprises at least one three-dimensionally contoured lateral surface,mated with complementary three-dimensionally contoured lateral surfaceof the adjacently mounted block.
 2. The method as set forth in claim 1,further comprising generating the common surface contour by a finishingprocedure, which comprises a milling of at least some of the foamblocks.
 3. The method as set forth in claim 2, wherein the finishingprocedure further comprises a forming a surface layer on the milledcommon surface contour.
 4. The method as set forth in claim 1, whereineach of the foam blocks are formed from a material dimensionally stableup to a temperature of at least 140° C.
 5. The method as set forth inclaim 4, wherein the material comprises at least one of a pourable epoxyfoam, a polyurethane foam, a glass foam, a high temperature resin, or athermoplastic material.
 6. The method as set forth in claim 1, furthercomprising storing the plurality of foam blocks in a preordered mannersuch that foam blocks of one and the same type are stored in a samestoring region before the mounting of the plurality of foam blocks tothe support structure.
 7. The method as set forth in claim 1, whereinthe support structure has the basic shape of the negative mold.
 8. Themethod as set forth in claim 1, wherein the predetermined number numberof different types of foam blocks does not exceed
 5. 9. The method asset forth in claim 8, wherein the predetermined number number ofdifferent types of foam blocks does not exceed
 4. 10. The method as setforth in claim 9, wherein the predetermined number number of differenttypes of foam blocks does not exceed
 3. 11. The method as set forth inclaim 1, wherein foam blocks are mounted to the support structure viaglue.
 12. The method as set forth in claim 2, wherein each of the foamblocks are formed from a material dimensionally stable up to atemperature of at least 140° C.
 13. The method as set forth in claim 12,wherein the material comprises at least one of a pourable epoxy foam, apolyurethane foam, a glass foam, a high temperature resin, or athermoplastic material.
 14. The method as set forth in claim 2, furthercomprising storing the plurality of foam blocks in a preordered mannersuch that foam blocks of one and the same type are stored in a samestoring region before the mounting of the plurality of foam blocks tothe support structure.
 15. The method as set forth in claim 2, whereinthe support structure has the basic shape of the negative mold.
 16. Themethod as set forth in claim 2, wherein the predetermined number numberof different types of foam blocks does not exceed
 5. 17. The method asset forth in claim 16, wherein the predetermined number number ofdifferent types of foam blocks does not exceed
 4. 18. The method as setforth in claim 17, wherein the predetermined number number of differenttypes of foam blocks does not exceed
 3. 19. The method as set forth inclaim 2, wherein foam blocks are mounted to the support structure viaglue.
 20. The method as set forth in claim 15, wherein the supportstructure metal.